Starting to build this all-terrain vehicle, the author set himself the task of making a reliable car for moving around woodland. Since the main place of exploitation is forest, the all-terrain vehicle must be maneuverable, which means side-turn. One of the necessary conditions was the observance of dimension and mass, so that it was possible to transport an all-terrain vehicle in a trailer of a passenger car.
Materials and assemblies used in the construction of this all-terrain vehicle:
1) The wheels are removed from the Niva, the used pressure is about 0.5
2) Ant engine and gearbox with missing differential.
3) Chains for realization of final drive
4) Friction clutch baskets taken from the VAZ 2108
5) From vaz 2108 disc brakes were also borrowed.
6) Stars from IL 15 are dental.
7) 2 clutch discs
8) 2 brake discs
9) 2 crankshaft bearings
10) 2 double row hub bearings,
11) 2 calipers with pads
All paired items were taken from a classic vase.
The all-terrain vehicle is made on a system of two axles and has the following dimensions:
180 cm long
150 cm wide
Height 110 cm plus covered with an awning.
The weight without an awning and frame is 340 kilograms, and completely under 400 kilograms, which is very small, which means the all-terrain vehicle is light and the ability to get stuck on it somewhere is minimal.
A riveted body was made, which was sealed for mobility and through water barriers. The maximum speed of the all-terrain vehicle by land is up to 30 km per hour, by water it is only 1 km per hour, since the wheels do not sink deep and row very weakly, if desired, this can be eliminated by installing a boat motor.
Consider in more detail the stages of construction of this all-terrain vehicle:
Starting the assembly of the transmission, the author used the maximum number of ready-made parts from standard VAZ models. As a shaft, a hollow pipe is used, which passes through the gear-reverse from Ant. Parts of input shafts with splines from the same classic AvtoVAZ models are welded to this pipe from both ends. Further, the design is included in the slots from the VAZ 2108, and the clutch baskets are fastened to the brake disc, and their diameters practically coincide in size. Therefore, the author simply made 6 holes and cut the thread for the m8 bolts.
Then, the disk with the basket already installed was attached with reinforced wheel bolts to the standard front hub of the VAZ 2108. The bearing was removed from the grenade located in the hub and a roller with splines was placed.Two stars from IL, which have 15 teeth each, are put on this roller. From one star, the drive goes to the front wheel, and from the second to the rear, respectively.
The flywheel of the knee shaft from the same vase was used with native bearings that are inserted into the cage. The author turned the holder on his own and welded it to the washer with 4 holes for the bolts. Thus, the washer is screwed together with the clutch basket, as well as the brake disc, which is quite convenient.
The hubs in the assembly with knuckles, as well as the gearbox, are mounted on a common frame. Clutch drives are mounted on the same frame. With such a scheme, the tension of the chains is due to the selection of gaskets between two frames: transmission and main.
This is what the dashboard looks like
The all-terrain vehicle was tested on snow and showed good cross-country ability with a clearance of 34 cm. Also, the author uses the all-terrain vehicle to clean the snow, for this I have to load it a little overweight. It’s going well on water, but the speed is very low, and it’s hardest for an all-terrain vehicle to drive on a damp arable land, too much dirt sticks to the place between the body and wheels, so such obstacles are overcome only in first gear.
The image above shows the details of the structures described:
1) fist swivel in a fixed position
2) Brake disc as clutch baskets
3) Main brake disc
Blue bearing
Yellow stars
Green- clutch, or rather basket
Red is the clutch disc itself
Purple hub
Brown-bolts
In principle, the scheme used is not bad enough, although it would be possible to use baskets and disks from UAZ or Volga, they are more than eight, which means it would be easier to increase the torque transmitted to the wheels. Since the torque is proportional to the gear ratio from the transmission, it is clear that in this design all the power of the engine is distributed equally between the sides. Therefore, with a gear ratio of two, the clutch will work fine and experience less stress. However, when the third main gear is engaged, the gear ratio increases several times, that is, at the third speed it will be under 10, which means that fast driving leads to increased adhesion loads, which is not so bad in principle, since you usually will not accelerate much in the forest, and on a flat road this is not a problem. In extreme cases, it is possible to replace the VAZ engine with a weaker engine, for example, from the Oka.
Here is a photograph of the hub assembly.
For its assembly, the following details were needed:
1) Axle shaft from GAZ-24
2) Grenade from the VAZ 2108
3) The hub from the VAZ 2108, which was sharpened for the bearing
4) The sprocket from IZH was fixed by welding to the hub.
5) Tapered bearings were also taken from gas-24.
6) The seals of the front hub from the same GAZ-24
7) The body was turned, 0.5 liter of oil was poured, and the flange was welded
A chain from the ant goes to the reverse from the engine, since a star is installed on it from the ant on the reverse gear. But with the stars on the engine, the author experimented quite a lot, and in different conditions they manifest themselves in different ways the characteristics of the machine. The motor chain is pulled by moving the frame to which the engine is attached, the frame can move forward and backward.
In the end, the author settled on a standard 15 tooth chain for the engine, the maximum speed on it is about thirty kilometers per hour. Although when installing a star on 17 teeth, the maximum speed naturally increases, but the author believes that traction for an all-terrain vehicle is still more important. There were also experiments with stars of 9 11 and 13 teeth. In general, after testing the machine, it was noticed how much reliability is needed when operating in such conditions. Thanks to its robust frame, you can not worry about the integrity of the machine and easily push branches on the forest path. The all-terrain vehicle turned out to be quite maneuverable, which means it is confident in cornering. Boarding and disembarking passengers is quite simple due to the design of the frame. Yes, the all-terrain vehicle does not have a cabin, but the weather protection in the campaign is still provided in the form of an awning and a structure for its installation on the all-terrain vehicle.
As for the hub housing, it was completely machined, although it was much easier to make it from pipe trimming, but in terms of reliability, such a design with welded bearings and seals looks better. 150 grams of gear oil was poured into the case. The drive chains are located inside the body, and all this is covered by a raised floor, and in the picture below the floor was dismantled for clarity.
Photos of the off-road vehicle:
Video of the first tests of the all-terrain vehicle:
The author of the all-terrain vehicle Andrey with the nickname "avtohirurg" from the city of Korolev, Moscow Region.